Method of making metal-clad counter tops



Feb. 19, 1952 G. H. NoRQUlsT METHOD OF MAKING METAL CLAD COUNTER TOPSFiled Feb. 10, 1947 10 Sheets-Sheetv l INVENTOR. filma /Vafyafs BYllTTd/IWEY.:

Feb. 19, )51952 G. H. NoRQUlsT 2,585,961

METHOD OF MAKING METAL CLAD COUNTER TOPS Filed Feb. 10, 1947 l0SheeiS-Sheet 2 Feb. 19, 1952 G. H. NoRQUlsT 2,585,961

METHOD OF MAKING METAL CLAD COUNTER TOPS Filed Feb. 10, 1947 lOySheenS-Sheel 3 INVENTOR ATTORNEY;

Feb.- 19, 1952 G. H. NoRQUlsT `2,585,961

METHOD OF' vMAKING METAL CLAD COUNTER TOPS Filed Feb. 10, 1947 l0Sheets-Sheet 4 ,n i B L f i W fw;

f ff a ATTORNEY.;

Feb. 19, 1952 G. H. NoRQUlsT METHOD oF MAKING METAL CLAD COUNTER Tops 10Sheets-Sheet 5 Filed Feb. 10, 1947 INVENTOR lffm linfa/'gaaf ATTORNEYJFeb. 19, 1952l G. H. NORQUIST 2,585,961

METHOD OF MAKING METAL CLAD COUNTERl TOPS Filed Feb. 10, 1947 10Sheets-Sheet 6 INVENTOR.

HTTORNEYD` Feb E9, i952 G. H. NoRQUlsT METHOD OF MAKING METAL CLADCOUNTER TOPS Filed. Feb. l0, 1947 1o sheets-sheet 7' Mamma/MM FITTORNEYSFeb. 19, 1952 G. H. NoRQUlsT 2,585,961 METHOD OF MAKING METAL CLADCOUNTER TOPS Filed Feb. l0, 1947 lO Sheets-Sheet 8 INVENTOR. zy z Z5 f?TTU/PNEYS Feb. 19, 1952 G. H. NoRQUlsT 2,585,961

METHOD OF' MAKING METAL CLAD COUNTER TOPS Filed Feb. l0, 1947 l0Sheets-Sheet 9 f5 t ,eff Il Z668 71 70 12g 7g [1M [126 k69 (117JNVENTOR. I

` 612.1111 /Vafgm's BY M ,glw dan/ Feb. 19, 1952 G. H. NoRQUlsT2,585,961

METHOD OF' MAKING METAL CLAD COUNTER TOPS Filed Feb. 10, 1947 :Losheets-sheet 1o INVENToR. filma /.jl/'aryuzls BY @dal Wma MM PatentedFeb. 179, 1952 METHOD OF MAKING METAL-CLAD COUNTER vTOPS Y 1 GlennH.NorquistgJamestoWmNQY.

Application `iebruary 10, 1947, Serial fNo. 127%585 This inventionrelates to an improved .method of :making-metal v clad counter .tops .ateconomical cost. Y

yMetal clad counter .tops .of the'vtype .hereinz illustrated as finished:articles of manufactnralare disclosed and claimedinmy'copending..applications .Ser.No. 7.27,-582, ledr'llebruary 10,1947(noW'PatentNo. 2,539,462.) a11dSer..No.,-727',58.3, filedy February1.10, .21947. -(now. Patent. JN0.

25399163). These metalclad .counter vtops may be for-med from asinglesheetof light .gauge metal stiflened andl supported by fibroushacking .sections to presenta table section havnga .splash sectionrising from oneftedge thereof. '.I'l'lestalole sectionv may be providedwith one or .more .sink wells `bonded to the-metal facing'sheetthereofwhereby the construction .providesactable sink of vlasting 'utility `andpleasing. appearance. .The perimetenpf the-table.. section is.desiraloly:pro-v videdwith a raisedfrim formation .Wherebyaithetop-surface of lthe table `sectionpresents drain board areas surroundingthe'sink well.

The metalfacing sheet is -formedhsovasctorcover the-exposed 'faces ofboth the table-portion :and the splash portion to V`provide `4al`construction free fromfvisible seams, allmetalfacing-.surfaceslbeing-'backed 11p/and supported 'by-fibrous back-ingsections sof that the metall facing surfaces cannot readily Abe Adented1orwtleformecl. The metal: facing sheetA `selected ispreferably formedfrom-abright metal, suchf'as stainlesssteel, Monel-metal,- aluminum,brass `or copper,-Whiohmaybel polished and finished on the^^top-sideprior "tocutting,- shaping `and bendingthereof VAfter the `metal facingsheet Lhas beenfpolished,vv the sink Well opening is--cut-`tlfie1'ein-'andE fthe corners thereof cut to the proper contour.-Afibrous backing -panel is fadhesivelybonded toi the rear `unfinishedface 'of the metal facing sheet. Thefnbrous backing panelmaybe-formed-from laminatedaply-Wood,` hard pressed liber-board,composition board, or like broussheetingrcome monly-used inthebuilding.' industry. The brous backing-panel-comprises a tablebackingsection, front andy side apron-.backing-sectionsiand splash `backingsections shaped to closely conform tofthe corresponding sections of the@metal facing sheet.

The apron backing sections, :as :bonded-to theV metal facing sheet, .arespaced from theadjacent edgesfofv thetable backing .section by..an-.fopen groove of. predetermined, width. vThe 4.elongated edgelofaeachuapronrlbacking :sections-next adj acent theitable. backing.:section:` isV also .-zheveledmr 4 Claims. (01..,29-148) slopedWithfrespect to/'the metal attachingaface thereof. The backing .panel asbonded .-to @the metalfacing sheet, thus vpresents the apron..back ingsections thereof .in spaced relation .to thetable y backing section yinamanner to permit .theformafrtion ofthe raised rim; which is to.extendV,aronnil the front and .side edges of the-table, sectipnf ther-metalsheet when .the connter.-top1..c0nt12uc .tionhas beenformed.

a The splashV .backinggsectionias bondedto the metal facingsheet;:presents a ilongirtndinalggedge spaced from the Iadjacent `irsearedge. pf;-thetab l e backing .section `by an. openeroore nf safprede:terminedl width .to -permit curvilinear-shaping of the splash sectionof. thefmetalfacingisheet. 1. i Bhe splash ybacking section. aszsecuredg-.t the'fmetal facing 1 sheet, isalso provdedwithlongitudinally Yextending* N :groove to ,deneahelfsbackr ing section`which 2 provides .support fion the. drop shelf sectionofthe/metalgffacineisheet. :zIranse versely, extending V.groovesare-cutdnzthe splash backing section to provide endbacking-sections for the end .splash sections V.ofkthe metal facingsheet. The shelf section zand end l-sectionsfifof the .metalfacingsheet.:are:.alsofzpnoyidedyswith inturned `ilange :sectionsfwhich.ma by .brons backing sections adenedib V grooves cutin thebackingpanel. Themetal -zapromsec.- tions are .also .preferably providedwith `intnrned. flange sections which mayabeucorered by backingsections. defined by: yVggrooves acuta in rtheJoacking panel.. t

.As .one method offlmanufactnre .of fthezzsbackf ing panel,theitablerbackingssection; eaclnof;fthey apron .backing sections :andthe @splash-1 backing section :may `:be:.forizrredfzto `Athe.-reqnirecl.eshapezas individua-l.y backing- .elements'nthe ,backinglejments` then fbeing connected :.ftogether; ini fche proper spacerelationship by meansfgof remera-f ble fasteners, aso -thatthe,-:composite'ahacking panel thus formed-mayfrbe adhesivelyfbonded as9, composite-.unit to :.thesmetal: facingfsheet. @The Vl Igrooves fin;the splash :backing sectiony which definev the. shelf backing sectionAand thefgend backingY sections 4of Vthessplashfupanel':manwloencnt intothe splash backingelement-eitherqbefpre or after this element:has:beengsecuredm-to the splash panelportion .of fthe -metal facing'Sheet.

In event the :inturnedwilanges .ofithe-zsplash panel portion of they'metalfacingrsheet arealso to be covered by brousbacking,y th :splashbacking element is made .ofl sufiicienttsizeftoalso cover thesemetalflanges, ;V .grooves-being@ tgin thesplash. backing element.eitgherfbefore orgafter the splashbacking element hasfbeen adhesivqelyVbonded to the metal facing sheet to permit bending formation of thesesections. If the inturned metal anges associated with the apron sectionsof the metal sheet are also to be provided wiht fibrous backing, theindividual apron backing elements are made of sumcient size to cover theassociated flange sections of the metal sheet, the flange backingsections being defined by V grooves cut in the apron backing elementeither before or after the individual apron backing elements areadhesively bonded to the corresponding areas of the metal facing sheet.

As a modied method of manufacture, a one piece backing panel may beprovided which is initially substantially rectangular in form, and fromwhich the sink well opening is cut out and the corners of the paneltrimmed off and sloped to the proper contour. Open grooves are cut inthe unitary panel to dene the adjacent edge contours of the tablebacking section and the adjacent apron backing sections and splashbacking section. Connecting neck portions extending between the apronbacking sections, the splash backing section and the table backingsection are left uncut, so that the entire backing panel will hangtogether as a unit when adhesively bonded to the rear face of the metalfacing sheet. When the backing panel has become firmly bonded to themetal sheet, the connecting necks are cut out so that the apron backingsections, the splash section and the table backing section are separatedfrom each other. The V grooves may then be cut in the metal facedbacking panel to dene the shelf backing section and the end backingsections of the splash panel.

irrespective of which method is followed in initially shaping thebacking sections, the table backing section, apron backing lsections andsplash backing section are adhesively bonded to the rear face of theprepared metal sheet in the proper spaced relationship for the countertop to be formed.

The metal clad panel with the backing sections properly formed, isplaced in a die press and the front and side edge portions of the tablesection of the metal sheet, unsupported by fibrous backing, are formedinto a raised rim extending around the front and side edges of the tablesection of the metal facing sheet. The open grooves or channels definedbetween the adjacent edges of the table backing section and the apronbacking sections and the splash backing section are so spaced andarranged as to permit shaping of the metal clad panel to providedepending apron sections and an erected splash section. A bondingadhesive may be applied to the open grooves and V grooves of the metalbonded backing panel prior to bending formation of the metal clad panel.

The metal clad panel may be initially shaped in a clamping frame whichserves to bend the apron sections into position substantially at rightangles to the table section, and additionally operates to bend the topshelf section and the end sections of the splash portion into positionsubstantially at right angles to the main splash section. In thisforming operation, the longitudinally extending beveled edges of theapron sections will fold over into the adjacent open grooves and will bebrought into abutment against the rear face of the adjacent raised rimformations of the metal sheet to provide a rxn backing support therefor.The shelf section and end sections of the splash portion are bent alongthe adjacent V grooves formed in the backing panel so as to extendsubstantially at right angles to the main splash section. While theapron. sections of the table portion, and the shelf section and endsections of the splash portion, are still retained in fixed position bythe clamping frame, the flange sections of the metal sheet associatedtherewith are turned inwardly and stiening strips inserted to t snuglyunder the inturned flange sections. The stiffening strips are assembledto provide a stiiiening frame extending around the inside face of theapron backing sections, and a second stifening frame extending aroundthe inside face of the shelf backing section and end backing sections ofthe splash portion. The inturned flange sections associated with theapron sections may be secured to the adjacent stiffening frame as bynails or screws, and the inturned flange sections associated with thesplash portion may likewise be secured to the adjacent stifiening frameas by nails or screws.

The thus partially assembled counter top, having the splash section andtable section lying in substantially the same plane, is then removedfrom the clamping frame, and the bonding adhesive previously applied inthe open channel grooves and V grooves of the backing panel is permittedto harden and set. The splash section is then erected around anelongated mandrel having a rounded edge which gives the metal sheet arounded curvature between the table section and the main splash section.A wood stiifening bar is then fitted against the rear uncovered face ofthe curved portion of the metal sheet located at the base of the erectedsplash portion. The stiffening bar is so shaped that the adjacent endsof the side stiiening strips underlying the table section, and theadjacent ends of the side stiffening strips underlying the main splashsection, will abut against the stiiening bar in position to be securedtheret0. As thus constructed the splash section will be rigidly formedto extend substantially at right angles to the table section, both thetable section and the splash section being also rigidly reinforced bythe underlying stiifening frames.

The sink well, which may be formed from a single sheet of bright metalstamped to the desired well contour, is then placed in position and theupper edge thereof bonded to the peripheral edge which denes the sinkwell opening in the table section of the metal facing sheet.

Fibrous ller boards are then employed to fillY the space within thestiiening frames previously applied to the table section and splashsection, which ller boards further strengthen the construction.

The metal facing sheet is provided with lip portions extending from theadjacent ends of the apron sections thereof which are folded over theadjacent inclined ends of the apron backing sections while the metalclad panel is still in flat form. When the apron sections have beenshaped to extend substantially at right angles to the table section,the. adjacent lip portions of the metal sheet will be in face-to-facecontact and extend diagonally inwardly from each of the front verticalcorners of the table top section. The metal sheet is also provided withsimilar lip portions extending from the adjacent ends of the shelfsection and end sections of the splash portion thereof, which lipportions are folded over the adjacent inclined ends of the adjacentbacking sections while the assegnare shelf i'sectionl-ar-i'dfendiJsec'tion-sfof the-.splashiportionv 'have been 'shaped =to extendsubstantially atrghtangles to 1 the rnainespl-ash r section there-- of.these adjacent lip portions will also be face-to-face contact'fandVnextend diagonally ;Y inwardly from-A each horizontal corner `edge ofIthe splash portion. A seam of soldering -or -vveldingV metal isiapplied to the f exterior surface of the vertical jointsy definedbetween the adjacent-lip Y portions-of-the apron sections, and a similarseamY off'solder 'or WeldingA metal isappliedlto theA exteriorsurfaceofA the i' horizontal joint defined between-the adjacent lipportions* ofth`esp1ash section. The VVmolten metal seeps inwardly-bevtween 1tl1eadjacent lip portions-to irmly bond thevadjacentA lip-portions into integral union.

The exterior surfaces of these metallic seams* nayJbe burnishedorpolishedto` giveethese four corneredges a-r roundedand nishedappearance. v

The fibrous Y backing sections bonded vtothe rearl face vof the metal'facing Vsheet prevent Wrinkling, warping' or-oth`erv undesired"distortions of the metal sheet during shaping and bendingthereofA intocounter top form, -andin addition'insure stiifness,v strength andrigidity to' the construction 4provides` a sound deadeningl eiect sothat the metal faoingesurfaces'Will-not reverberate orf'produce-ametallic ring when drummedupon; and inaddition permit-the use `of arelatively light gauge'facing sheet which can be"`worked"`andshaped"with relative ease. The"stiffning"frames "and 'filler boards appliedto'the table section and 'splash section, furtherA enh/ancethe rigidityandstrength `of the countertop Without"substantially increasingtheweight ofthe construction; 'Thisiimprovedcounter top thus 'presentsall"'th'e"'exposed surfaces thereof covered 'by anV unbroken'metalliclayer Whiclrmay be made' of bright metal and' thuscan be easily cleaned'and kept in 'a highly sanitary condition.

An object of this invention' is to provide an improved `Vmethod for theAproduction of 4high quality 'metal 'clad counter VtopsVlr2wi1ig'"apron'ed table sectionsSby-hi'gh speed YmassY productionloperations; with" a v minimum" 'of laborand Va minimum use of'm'ateriaI,and'at lowcost;

.Other object s 'and advantagesv of `this invention will" becomeapparent -as the 'disclosure' proceeds.

Although the characteristic 'features Yof "the vention .will beparticularlypointed out inthe claims appendedl hereto; the inventionitself, and

the 'manner.in. which it may be carriedA out, may' be better'understoodby `referring tothefollovvv` ing description taken" inconnection with1 the accompanying drawings forming a part .thereof,

in which' filler" boards; thisview illustrating lthe sink `vvell as':attached i tof the undersideof. 'the' A--sheet f metal facing-Whichsurfaees-the table-section;

1!ig..:.5. isf anv `underside eviewfof 'thai-fully fas-v sembledlcounter '.top, a 1 corner section :thereof being partially :broken awayto illustrate further..

structural details thereof.

Fig. V6 isriazrear. face :View` ofithe splash-'section of-lthefullyiasseirnbled counter. itop;A aucorner :seca

tion thereof.4 being1partially` broken awazvatoi'Av i1 lustrate certainlstructural details .thereof Fig: 7 i is a longitudinal.` cross.ysectional view-Tof the= splash4 section Vof the. fully.y assembledcounter.: top asthe same Wouldappear: Whenlviewedcalong.:

line 1 1 of Fig. 1.

Fig. 8l is 1a plan viev/f ofy thereotan'gular` shaped metal sheetpolishedA on oneside: thereof only,

used -in the fabrication of-this improved-counter..

top.r

the table section thereof.

Fig: V9a is a fragmentary perspective view-sil. lustrating the manner inwhich the lip portions" at the corners of the metal facinglsheetarebent; Fig.-10is a plan view of theY fibrous backing panel usedin-onemethodof constructing this` improved counter top.

Fig. 11Vv is la planview of thebacking panel showing the cornersthereof-cut-to 'fthedesired .con'tour," the panel havingbackin'g:section dening grooves cuttherein-wh-ieh dene thebaclz-V in'g-sectionsthereof, the Y table backing sectionY having the sink wellopening-cut v therein;

Fig. 11a is an enlarged fragmentary perspective view-of one ofthecorners of thebacking panel as thesaine would appear whenlviewedialongline lla-i la'ofFig'. 11.

Fig. 11b is a fragmentary-cross sectional'viewj' illustrating moreparticularly the neck 'portion'` which connects the apronandsplashfbacking sections'to the table backing section'fas'the same ofFig. 11.

Fig. 12 is a plan View showingV the'backin'g panel illustratediin Fig.1l adhesively bondedto the'metal facingsheet shown in-Fig'. 9; with theparts thereof in properregister. v

Fig. 13 is an enlarged fragmentary cross-sec-` tional'view ofthe metalcladpanelshown'in Fig." 12 as the same would appear' when viewed alongline l3-l3 of Fig. 12.

Fig. 14 is an enlarged fragmentary transverse crossesectional vievv ofthernetal clad' panel/as the'A same would appear Awhen* lviewedalongline Fig. 15 is'a plan' view` of the -rnetal'clad panel shownn'Fig.' 12 afterthe V-shaped grooveslh'ave been cutinf'the backing panelandl afterthemetal lip portionsV have been bent to theiriinal position;providing a metal clad panel ready"for-shaping operations;

Fig. 16 is a plan view of a fibrous'backing panel of `modified form',this backing panel comprisingl separate backing sectionsconnected'-.ii`rproperA5 spaced relationship by. corrugated'fasteners.

Fig. 17 isa planview of'the^modified"backing panel as shown in Fig. 16after the-samefhas beenA adhesively bondedto a metal facing sheet-of-theform shown in Fig. 9.

Fig.' 17a is anl enlarged fragmentary perspective ViewA showingafragmentary portion of the table backing section and anadjacent apronbacking section with a corrugated fastener in-positionto be drivenk intoVthese sectionszto connectthe sam toaprovide a..unitaryipanel-ly 1 Fig.9is1a plan view ofithemetal facing sheet asthe@ same #would appear afterthe corners thereof have been cut-'to the: desired contourland`'-aftenthe'vsink well opening has-:beenruit from Fig. 18v is a plan viewof the metal clad panel at a further stage of assembly, this viewparticularly showing the rim formations formed in the metal facingsheet.

Fig. 19 is an enlarged fragmentary cross-Sectional View of the metalclad panel as the same would appear when viewed along line |9-l9 of Fig.18 and having a backing panel in the form shown in Fig. 15, this viewalso showing diagrammatically a cross section of the dies employed i toform the side rim formations in the metal sheet.

Fig. 20 is an enlarged transverse cross-sectional view of the metal cladpanel as the same would apear when viewed along line 20--20 of Fig. 18and having a backing panel in the form shown in Fig. 15, this view alsoshowing the dies employed in forming and shaping the front rim formationin the metal facing sheet.

Fig. 21 is an enlarged longitudinal cross-sectional view of the splashsection of the meta clad panel as the same would appear when viewedalong line 2l-2l of Fig. 18 and having a backing panel in the form shownin Fig. 15.

Fig. 22 is an enlarged longitudinal cross-sectional view of the metalclad panel formed as shown in Fig. 18, this panel having been formed bythe employment of a fibrous backing panel in the form shown in Figs. 16and 17.

Fig. 23 is an enlarged transverse cross-sectional view of the metal cladpanel formed as shown in Fig. 18, this metal clad panel employing abacking panel vin the form shown in Figs. 16 and 17.

Fig. 24 is a perspective view of the metal clad panel shown in Fig. 18as the same would appear after the front and side apron sections of themain table portion, and the shelf and end sections of the splash portionhave been shaped into formed position.

Fig. 25 is a longitudinal cross-sectional view through the table portionof the partially formed counter top as the same would appear when viewedalong line 25-25 of Fig. 24.

Fig. 26 is a transverse cross-sectional view of the partially assembledcounter top as the same would appear when viewed along line 25-25 ofFig. 24.

Fig. 27 is a longitudinal cross-sectional view of the partially formedsplash section as the same would appear when viewed along line 21-21 ofFig. 24.

Fig. 28 is a rear face View of the partially formed counter top afterthe addition of the stiffening strips, this view additionally showingcertain elemental details of the clamping frame employed in shaping andretaining the apron sections surrounding the table section, and theshelf and end sections of the splash section, in formed position.

Fig. 29 is an enlarged longitudinal cross-sectional view showing furtherdetails of the clamping frame, this view also showing the sidereinforcing strips as inserted under the inturned side flange sectionsof the table portion, as the same would appear when viewed along line29-29 of Fig. 28.

Fig. 30 is an enlarged transverse cross-sectional view showing furtherdetails of the clamping frame with the stiffening strips inserted underthe front flange section and the rear splash flange section, as the samewould appear when viewed along line 30-30 of Fig. 28.

Fig. 31 is a longitudinal cross-sectional view of the partially formedsplash portion showing further details of the clamping frame andthe sidestiffening strips inserted under the inturned flange sections of thesplash portion as the same would appear when viewed along line 3l-3I ofFig. 28.

Fig. 32 is a perspective view of the counter top illustratingparticularly the manner in which the splash portion is shaped to extendsubstantially at right angles to the table portion thereof.

Fig. 33 is a transverse cross-sectional view through the formed splashportion and table portion as the same would appear when viewed alongline 33-33 of Fig. 32, this view additionally showing a cross section ofthe splash forming tooll and a cross section of the rear stiening bar inposition to be applied to the rear face of the rounded metal corner atthe base of the main splash section.

Fig. 34 is a fragmentary perspective view showing one end of the countertop and the corner shoe prior to application to the counter top.

Fig. 35 is an enlarged fragmentary cross sec-l tional view through thefront apron section as the same would be formed from the metal cladpanel illustrated in Fig. 17; and

Fig. 36 is an enlarged fragmentary cross-sectional view of the sideapron section as the same would appear when formed from the metal cladpanel shown in Fig. 1'7.

Similar reference characters refer to similar parts throughout theseveral views of the drawings and specication.

The improved counter top construction, as generally illustrated in Figs.1 to 7 inclusive, comprises a metal clad table section a which may haveone or more sink Wells b positioned and a1'- ranged therein as may bedesired. If equipped with a sink well, the metal clad table section awould present side drain portions a at each side of the sink well b, afront ledge portion a" extending at the front of the sink well b, and arear ledge portion a" extending along the rear edge of the sink well b.

The table section a merges smoothly into a rear splash section c whichmay rise any desired distance to protect the building wall adjacent towhich the counter top is mounted. The front edge of the table section amerges into a downwardly extending apron section d, and the side edgesof the table section a merge into downwardly extending apron sections e.The vertical splash section c merges into a horizontally extending shelfsection f and into vertical end sections y. The front edge and the sideedges of the table section are surrounded by a raised rim happroximately #s to 1/4 of an inch in height and adequate to preventliquids deposited upon the table section from overflowing to the floor.The front and side apron sections d and e are pro- J vided with inturnedange sections k and r respectively, and the shelf section and the endsections g of the splash portion are also provided with inturned flangesections s and t respectively. Shoe sections i may be secured to therear corners of the counter top to further stiffen and strengthen theconstruction and give the same a finished appearance. The'rear ledgeportion a of the table section a may be provided with suitable openings7' for the convenient attachment of faucets and like plumbing fixtures.

Improved counter tops made in accordance with this invention aredesigned to be mounted upon floor cabinets, restaurant and bar counters.tables and like supporting structures S, as typically illustrated inFig. 1, to provide a combined 9 tableztop; andi-splaslrz panel therefor.The ftable section .may alsoi bevprovided-v witlr` one. or :more sinkWellsz-if so desirede.y This improved counter topis adapted-.to bezxe'd.and secured-tothesupporting structure by concealedT` fasteners,providinga construction which is fstrong i and durable, light in weight,pleasing in appearanceandihighly sanitary; with all vexposedsurfacesthereof. covered by a metalfacingwhich-.is smooth and free from'crevices or visiblelinesfofjuncture.

Counter tops of "the-'type generallyabovedescribed 'may be economically`fabricated and? constructedfroma metal facingrsheetm of relativelylight gauge metal, .preferably a brightl metal, which needA not have-agreater'thicknessthanf 18 to30 gauge. The metal facing sheetis backedup, reinforced-and. stiffened. by a -brous backing panelzp which maycomprise laminated plywood, or other hard. and durable sheathing', usedin the building. industry: The metal facing. sheet m may be purchasedunfinished and: unpolished; cut to rectangular shape: of .sufficientdimensions to form the desired counter top; Themetalfacingi-sheetissanded orpolished to the desired finish on one sidethereof only as shown in Fig. 8, preferably before any cuttingorfabrication operationsv are performed thereon..

Asf-an initial step in theV fabrication, the metalsheet .ml shown inFig.-8 is placed. in. a press and the corner portions `'rn/removedleaving.- shaped corner edges as. shown inFig. 9. Shortslits 24 are-cutdiagonally into` each. of` the front corners of the metal sheet anddiagonally extending slits 34f-.are cut into the rearcorners of themetal sheet.. Apair of longitudinally ,extending `slits 25 are cut inthemetal sheet toextend inwardly a predetermined distance from each sideedge thereof.. A sinkwell opening8 of. desired'size is cut outfrom thecenter section of the` metal sheet in. event the sink. well is. to .beprovided in the countertop as -iinally constructed.

As thusformed, the metal facing sheet as shown inlFig. 9 presents atablesection .I, a front apron section .iy dened by the longitudinallybending line, andside .apron sections 20- deflnedbyl the generallyparallel extending bending line 5. The frontapron section I5 is providedwith a iiange section l5 denedby a bending line. I1' and the` sideapronsections 20' are each provided with.

a 'angesection. 2l dened b'ya bending line 22. A main splash section 2extends along therear edge `oi" the tablesection. l, defined by abending bandi.y A shelf section 32 de iined by bending line sextendsfrom the longitudinal edge of the Amain splash section .-2, .and an endsection26 extends from` each.l end of the mainsplash section 2, eachdened by bending linel'l. Each end section 25 is `provided with a sideflangesection 28 defined byfbendingline 29:; andthe longitudinal edge'ofthe shelfsection SB-is provided with aange section 35 dei-ined by`bending line.36-.-

Alip portion l-extends from each endof the front apron section l5 andrisdefined by a bending'- line 5 substantially in alignment with adjacentbendingline. 5. The front end of each of theside apronsections Zcis-likewisecprovidedWith a lip portion. 23l denedby a bending line@substantially. inalignment withY the bending line 4. Each' end? ofythe.v shelf section 32 of the splash portion of the .metalzsheeti isyprovided' 'with a lip portion. -dened-:bya bending'line'.''lfsubstantially in. alignment with thezadjacentrbendingflineiffZl. Theu-pper .'endiof. eachxendfsection 2id isalsof providedwith .a lipportionfiuzdeinedby av bending line 33 rsubstantiallyin.alignrnentzwith` therbendingline 33: The adjacent lip portions 3d and 34are separated by the diagonally extending cut line 34 previouslydescribed which extends to the adjacent corner of the main splashsection 2.

that the bending lines 4 and Il, 5 and 22,3, 33

and 38 are4 shown in Fig. l9 merely to'indicate the linesv along whichthe'metal .facingsheet Will be bent in .later OrmingOperatiOnS. The lippor tions I8 and 23 maybe bent along the-bending lines-5' andl to extendupwardlyirom the rear face^of the metal sheet, as-shown more particu:larly'in- Fig; 9a, either before'or after the fibrous .backing panel isadhesively bonded tothe-metal facing sheet.` Similarly, the lip'portions 3(3and Sllfmaybe bent alongthe bending lines-33e and 2:1' to.extend upwardly from the rearface'of the metal sheet. Where a sink wellopening 8 is'to be-provided, va surrounding'edge portion -of the tablesection l of the metal sheet may be pressedl to dene. a gently slopingflange portion 9 termi-l nating in a down turned lip portion I0, whichforming. operation mayrvbe executed either before or .after the backingpanel is 7bonded toY themetal sheet.. Where a sinkwell opening lsisprovidedv in:-th.eftableI section-I of the metal sheet; the sink-:Wellopeningmay beso'located that thetable section.- deiines suitable sidedrain areas a', a iront.` drain or ledge area a anda rear ledg area. a''as shown inFig; 1.

The. nbrous .backingpanelp maybe formed of laminated plywoodfhardpressed ber board, pressed. composition board, or like strong fibroussheathing-commonly used-in the building industry?. Theiibrous backing.panel pV is preferably approximately 1A inch in thickness,v althoughvit may vary. in .thickness from ,as low as- 1/8 oraninchto .1/2 rinch.or more.. ini thickness'.v

' Inlaccordance: Withv one manufacturing-=pro-- cedure. of thisinvention, a substantially rectangulanbackingpanelis provided as-shownin Fig. 10. Corner-.portions .p of--ithepanel` are removed on .acornernotching machine', and open grooves 43, 45and 6I. are cut in the Ipanelto-'dene the boundaries ofthe table backing section' l. I If thecounter. top is to be=provided with a sinlrwell,` a sinkAvvell'.openinggiI f -is cut from thetable back= ing .section 4l, Yasshownr in Fig.Y 11, to register with .the sink well Iopening 8 cut inthe tablesece tion..l oithe metal sheet. It will be notedthat thegrooves 43, 45 and 6I are so cutas to'present spaced necksllyY whichserve tohretain the backingsectionsdened' by these grooves together asaoneepeice'panelunit. It'willA be noted by 1e'4 ferringftorFig; 1lb,that each of the connecting nec-ks3'fare undercutas at 43" along themetal attaching'face of the backing` panel. The grooves 5.3545 and 6lpierce the panel soas to present open4v grooves lor slots' therein ofpredetermined' width.` The'outer"longitudinaledge 36 of the groove d'3'is cut'atanr incline of approximately 45 with respect to the metalatta'chin'g' face' of thezvbackingepaneli The' side groove 45 has alongitudinal-edged? thereof.` cut on an incliherof approximately 45 withrespect to the metal at# tac-hing? face'of'the'backing'panel. The groovelpresents substantially square cut longitudinal edgeseexteridingrati`-an anglev of 'approximately l1 90 to the metal attaching face of thebacking panel.

The backing panel thus presents a front apron backing section 42 and anadjacent flange backing section 48 defined by the marker line 49, asshown in Fig. 11. Each end face 50 of the front apron backing section 42is cut on an incline so as to present an end face extending at an angleof approximately 45 to the metal attaching face of the apron backingsection. Each end 5I of the front flange backing section 48 is cut on abias extending at an angle of approximately 45 to the groove marker line49. Each of the open grooves 45 define a side apron backing section 44to which may be attached a flange backing section 52 defined by thegroove marker line 53. The front end of each side apron backing section44 is cut to present an inclined end face 54 substantially in line withthe adjacent slot groove 43. The front end of each flange backingsection 52 presents a square end face 55 which extends at an angle ofapproximately 45 with respect to the adjacent groove marker line 53. Thegroove marker lines 49 and 53 dene the location of V grooves which willbe cut in the backing panel either prior to attachment of the backingpanel to the metal facing sheet, but preferably after the backing panelhas been adhesively bonded to the metal facing sheet.

The splash portion of the backing panel is defined by the open slotgroove 6I and presents a main splash backing section 60, a shelf backingsection 62 defined by the groove marker line 63, and may also have anassociated flange backing section 64 defined by the groove marker line65. An end backing section 68 extends from each end of the main splashbacking section 60 and is defined therefrom by a groove marker line 69substantially in alignment with the adjacent open groove 45. A flangebacking section 1U may be provided which is defined from the adjacentend backing section 68 by a groove marker line 1I. The upper end face 12of each end backing section 63 is cut at an angle of approximately 45with respect to the metal attaching face of the backing panel. The upperend of each of the associated flange backing sections 10 presents asquare cut end face 13 which extends at an angle of approximately 45with respect to the adjacent groove marker line 1I. Each end of theshelf backing section 62 is also sliced off to present an inclined endface 66 which extends at an angle of approximately 45 to the metalattaching face of the panel. Each end of the associated flange backingsection 64 is cut to present a square cut end face 61 which extends atan angle of approximately 45 to the adjacent groove marker line 65.

As thus cut and formed the backing panel p as shown in Fig. 11 presentsbacking sections shaped to closely conform in area to the correspendingmetal facing sections of the metal sheet shown in Fig. 9 to which thebacking panel is to be applied. A film of bonding adhesive isinterleavened between the metal facing sheet and the backing panel, andthe bonding adhesive then permitted to harden and set to securely bondthe metal facing sheet to the backing panel as shown in Figs. 12, 13 and14.

The connecting necks 43 of the backing panel are then removed so thatthe open channel groove 6I extends completely across the entirelongitudinal length of the backing panel as shown in Fig. 15, thechannel groove 6I exposing the bending line 3 and the aligned slits 25of the 'marker lines 49, 63 and 65 respectively.

metal facing sheet. The connecting necks 43 are removed from the channelgrooves 43 and 45 so that the ends of the front channel groove 43 willintersect the adjacent ends of the side channel grooves 45, and the rearends of the side channel grooves 45 will intersect the open channelgroove 6 I, as shown in Fig. 15.

The grooves 43 and 6I may be initially cut on a line grooving machinehaving a pair of cutting Wheels, one of which is shaped to cut thesquare cut channel groove 6I, and the other Wheel employed to cut thegroove 43 presenting the inclined face 46. The same grooving machinelmay be used to remove the connecting necks 43 from these grooves afterthe backing panel has been applied to the facing sheet. 'I'he sidegrooves 45 are also initially cut on a grooving machine having twogrooving wheels, designed to cut the open grooves 45 so as to present aninclined edging face 41. The same grooving machine is used to remove theconnecting necks 43 after the backing panel has been bonded to the metalfacing sheet.v

It will be noted, by referring more particularly to Fig. 11b, that themetal attaching side of the connecting necks 43' is spaced from themetal facing sheet m so that the connecting necks are not adhesivelybonded to the metal sheet; a feature which permits the connecting necks43 to be easily removed with no backing fragments adhering to the metalfacing sheet. It will be appreciated that the open side grooves 45 areeach so positioned as to expose the adjacent side bending line 5 of themetal sheet, and the open groove 43 is so located as to expose the frontbending line 4 of the metal sheet. More particularly, the pointed edge41 of the inclined face 41 of each groove 45 is located so as to extendsubstantially in alignment with the adjacent bending line 5 of the metalsheet, and the pointed edge 46 of the inclined face 46 of the groove 43is located to extend substantially in alignment with the bending line 4of the metal facing sheet.

The metal clad panel mayA then be run through a grooving machineequipped with three grooving Wheels formed to cut the V-shaped grooves49', 63 and 65 along the parallel extending groove The panel is againrun through a grooving machine which may have four grooving wheelsadjusted to cut the V grooves 53', 1I and 69 to extend along the groovemarker lines 53, 1I and 69 respectively of the backing panel. As thusformed, the valley of the V groove 49 will directly overlie the bendingline I1 of the metal facing sheet, the valley of the V groove 63' Willdirectly overlie the bending line 33 of the metal facing sheet. and thevalley of the groove 65 Will overlie the bending line 36 of the metalfacing sheet. Simllarly, the valley of each groove 53 will overlie theadjacent bending line 22 of the metal facing sheet, the valley of eachgroove 69 will overlie the adjacent bending line 21 of the metal facingsheet, and the valley of each groove 1I will overlie the adjacentbending line 29 of the metal facing sheet. In event the sink well isprovided in the table section a, the sink Well opening 4I in the backingpanel is made somewhat larger than the sink well opening 8 in the metalfacing sheet, so that the surrounding flange portion 9 of the metalfacing sheet will not be covered by the table backing section 4 I.

The lip portions I8 of the metal sheet may then be bent to snuglyoverlie the inclined end faces 50 of the front apron backing section 42,and the lipiportionsiZSf-fof the s metal facing; sheetezmayabe swaged'iover the adjacentiinclined end.faces 54 of the sideapronba'cking;sections.44, as? illus-l trated in Fig. 15. Similarly, thelip portions 34 of vthe metal. sheet are svvagedV over the adjacentinclined end faces'GG of the shelf backing section 622,2.'and" the,mtalrlip portions 3 0 are swaged over theadjacent inclined end faces l2of the end backing sections 68 of the vsplash portion.'

The adjacent-ends of the metal front flange section i6 andthe sideflange sections 2| may also be provided with lid portions if desiredwhich are bent to snugly overlie the adjacent end faces 5I and 55respectivelyof the ange backing sections 48-and 52.' If desired,however, the flange backing'sections .e8 and 52 may be dispensed with.The vadjacent ends of the metal .top fiange section 35iand the sidezangesections 28= may also be provided with lip vportions ,to be bentover.the square cut ends Hand. 3'of the flange. backing sections t4- and. l0.respectively. Asa further modification.. the flange., backing sections64 and 'E0 may be eliminated, leaving the metal flange sections. 35 .and28 uncoveredv by the backing panel. vThe metal clad panel formed asillus, tratedin Fig. v15, or modified in the respects above indicated,is ready for shaping operations.

As' a practical alternative, the backingpanel p may beassembled'from apluralityof separate backing sections' by following the methodillustrated in Fig. 16. A table backing section 4I is provided which isgenerally rectangular in form and presenting square cutv edges of a sizeto accurately cover the table section I of the metal sheet Within theraised rim formations h thereof. A separately'formed frontapronbackingsection ll'v is cut to a size to accurately cover the rearface of the front apron sectionY Hiof the metal facing sheet.v Each endG' of the front apronzbacking section t2v is sliced on an incline so asto present an end face-Which'slopes atan angle of approximately 45'tothe metal attaching-face of the apron backing section. The longitudinaledge 46 andthe front apronv backing sectiony 42, which is to bepositioned next adjacent thetable backing section. di, is also cuttoprovide-a slanting face edge lit which extends. atan` angle of .approxifmately 45 to the metal attachingfa'ce of the apron backing section.

Separately formed side apron backing sections @it are provided of a sizeand shape to accurately cover theinside face of the sideV apron sections2U' of the metal facing sheet. Each of the side apron backingsections ithave the front end thereof out on a slope so as to' presentv an endfacing edge. 54. inclinedV atan angle of) about'45" with respect to themetal'attaching facel of theapron backing section. Each side apronbacking section M' has one longitudinal edge thereof cut inA an inclineso as to present an edgev face 47 which may be slightly rounded-andinclined at an angle of approximately 45C" to-the metal attaching'faceof theapron section.

A separately formed backing section for" the apron portion of theconstruction is also provided which presents a main backing' section 60and a shelf backing section 62 defined by the longitudinally extending Vgroove 63. A pair of end backing sections 63 are provided,` each ofwhich is defined from' the adjacent endY of the main splashbackingsection 6@ by a V groove 69". Each end, of the shelfbackingssection. V62.' is. designedtoV present an inclinedend face 66sloped at anangle of approximately 45 with respect to the metalattaching face-.of the section 62. The upper end 0f each of. the end.backing sections .63v is also. cut

14 Y toi present '.an'. inclinedzendi facezflzeinclined an: proximatelywith respect "tothe lmetalattacliel ingface thereof'.

It Willfbe noted byireferring. to Eig. .16,'Jthatithe table Ibackingsection 4I, the vapron backingtzsecetions Mfand, and-the splash backingsection havingzthe Vshelf backing section` (i2iand;end;ba'cl1:"iV ingsections .t8 associated therewith, mayibeisepae. rately cut and: formedVWitha minimumwaste' of material. These backingsections may :befcon-`veniently connected together when laid flat upon a Workbench providedwith suitable corner guide blocks vN30-whichperrnit convenientintertting of 'the' sectionsv as shown in Fig. 16. The longitudinallyextending-inclinededge 46 of the .front apron backing; sections 42- isrspaced from the adjacent. edge ofrthe. table backingA sections .14|- aspecinedi distance to provide an open groove43 therebetween. The widthof the open grooveul may beY accurately .defined by removable; Wedge.blocks i051 insertedv therein. The widthzof: the open:A groove 43 issuch .as to snuglyl receive v'the adjacent edge-i6 of the apron backingvsection.42 whenthe metal cladpanel is shaped intoxcounter tcpformxaswhereinafter described. The-.inclinedv longitudinal edge 4f ofeach of the side apron backing sections d4-are also accuratelyspaced,xas by the use of wedge blocks l0 I from thefadjacent edge of thetable backing section 4I so as to pro.' vide an open grooveA5-designedfto snugly receive the-adjacent edge llof the apronvsection'when the countertop has beenformed.

Thelongitudinal edge of the main apron. back--t ina section i may bespacedfrom they-adjacent rear edge of the table backing section 4I',vas'zby the use-fof Wedgey blocks- HH, so. astopreSent therebetween anopen groovel of predetermined width.. The V grooves S3 and 69 may be cutin thesplash back-ing portion of the backing panel either before orafter the backing panel has been adhesively bonded to the metal facingsheet.

The front apron backing section-.42, the side. apron backing sectionsM'and the splash backe ing section 66', accurately spaced by the definedopen grooves 1153-, l5 and 8| respectively, are tem-f porarily connectedto -the table .backing sectionv el by drivin-g suitable fasteners, suchas the .corrugated staple fastener IDZ shown more'particu.. larly inFig. 17a, into the adjacent edge portions ofthe sections'. The spacingassembly` ofv these. separate backingisections may be quickly performed' by the use of removable wedge blocks lil-l` and a simple`guideblock` arrangement as illustrated in Fig. 16 in itsl elementalform. The fas-x tenersm2 .firmly hold the sections together to provide apanel which cany be applied andradhe--z sively'bonded as a unit to themetal facing sheet as-shown more particularly in Fig. 17.

Whenv the' backing panelhas` been adhesively bondedV tothe metal facingsheet asshown more particularly` in Fig.-.17, the.table backing. section4l" Will `be"positioned to neatly cover-.the tablev section l ofV themetal sheetas deiined ,within the raised rim formations `h thereof. The`front apron backing section-42 will neatly cover-.the front apronbacking section l5 of the metal sheet; With-2 the'Y bending line llofthe metalrsh'eetin alignment with the edge vt6 of the inclined face t5of the apron backing section: 42.Y- Each side apron backing-section MWill 'be shaped-t0' snuglyicoverzthe side apron sections y20. of." thenieta-lwsheet, with the .bending line 5 of ther-metal# sheetin:alignment-With the adjacentedge"13'!! of` thefinclined face Atl-ofthefapronbackingsec-.z

tionfyJUL-.- Themain .splash.;backing.rsectiozrrfillwill cover the mainsplash section 2 of the metal sheet, leaving the bending line 3 of themetal sheet exposed along the open groove 6I. The end backing sections68 will cover the adjacent end sections 26 of the metal sheet with thevalley of the V grooves 69 aligned with the bending lines 21 of themetal sheet. The shelf backing section 62 will cover the shelf section32 of the metal sheet, with the valley of the V groove 63' overlying thebending line 33 of the metal sheet.

The lip portions I8 and 23 of the metal sheet may then be bent to snuglyoverlie the adjacent inclined end faces 50 and 54 of the backing panel,and the lip portions 30 and 34 of the metal sheet may be bent to overliethe inclined end faces 66 and 12 of the backing panel. The staplefasteners |02, shown in Fig. 17, are removed from the backing panelprior to shaping formation of the metal clad panel. It will be notedthat the metal flange sections I6, 2|, 35 and 25 of the metal facingsheet are not covered by corresponding flange backing sections in themetal clad panel as illustrated in Fig. 17. It will be appreciatedhowever that corresponding flange backing sections may be provided as inthe manner illustrated in the metal clad panel shown in Fig. l5. Inevent a sink well is to be associated with the metal clad panel shown inFig. 11, a suitable sink well opening can be cut in the table section Iof the metal sheet and the table backing section 4I of the backing panelin a manner so that the inclined flange portion 9, surrounding the sinkwell opening 8 cut in the metal sheet, would be exposed and not coveredby the table backing section 4I.

The metal clad panel constructed and formed as shown in Fig. 15 or Fig.1'?, is then placed in a die press which operates to deform theperipheral portions I2 and I3 of the table section i of the metal facingsheet in the manner shown in Figs. 18 to 23 inclusive. The rim formingoperation may be performed in one or more stages as desired by the useof one or more die presses, illustrated in elemental form in Figs. 19and 20. The die press is provided with a press table having a flat tablesurface |06 upon which the table backing section 4I is supported, andraised table surfaces |01 upon which the side apron backing sections 44are supported. The press is equipped with vertically reciprocating pressblocks |08, each having a die face |09 designed to press against themetal sheet directly over the open grooves 45 so as to bend and shapethe peripheral side edge portions I3 of the metal table section I to thedesired rim conformity.

In the same or in a second die press operation, the table backingsection 4| is supported upon the table surface |06 of the press tableand the apron backing section 42 is supported upon the raised surfaceII'0 of the press table as shown in Fig. 20. A die block III having adie face II2 operates to shape the front edge portion of the metal tablesection I to provide the inclined rim face I2. A die block I 3 having aflat die face I |'4 may be provided to exert pressure against the tablesection I and the splash section 2 of the metal sheet to hold the metalclad panel in proper position. The die blocks |08 and III may be soformed as to merge the adjacent ends of the rimmed faces I2 and I3 intoa smooth and unbroken corner bead |4. If necessary, corner die blocksmay be employed to insure the desired rounded and continuous contour atthe corners of the rim formation h. It will be noted that the splashportion of the metal clad panel will lie in the same fiat plane as thetable portion a after the raised rim faces I2 and I3 have been formed inthe metal facing sheet, as will be evident by referring to Figs. 18 to23 inclusive.

When the rim facing portions I2 and |3 have been formed in theperipheral boundary of the table section I of the metal facing sheet asillustrated in Figs. 18 to 23 inclusive, the metal clad panel is incondition for further shaping into counter top form as shown in Figs. 24to 27 inclusive. Immediately before the shaping operation, a strip ofbonding adhesive may be placed within the open grooves 43, 45 and 6I andwithin the V grooves 49', 53', 63', 65', 69 and 1|. Thereupon the frontapron section d, the side apron sections e, the end sections g and theshelf section f are shaped to extend substantially at right angles tothe table section a and the main splash section c. The flange sectionslc, r, s and t are also bent inwardly so as to extend substantiallyparallel to the main table section a and the splash section c. Thisoperation can be performed by hand or by a simple shaping jig orfixture.

As thus formed the open groove 43 will receive the adjacent edge portion46 of the front apron backing section 42 with the inclined edge 46snugly seating against the under surface of the raised metal rim I2 asshown in Fig. 26. The open grooves 45 will likewise receive the adjacentedge portions 41 of theside apron backing sections 44, with eachinclined edge 41 firmly abutting against the rear face of the adjacentraised metal rim formation I3 as shown in Fig. 25. The V groove 63between the splash backing section 60 and the shelf backing section 62will close to form a mitered'joint 63 as shown in Fig. 26. Each V groove69 will likewise close to form a mitered joint 69 between the endbacking sections 68 and the adjacent ends of the splash backing section60 as shown in Fig. 27.

In event the inturned flange sections of the metal sheet are supportedby flange backing sections as shown in Figs. 15, 25, 26 and 27, theinturning of the metal flange sections 2| will close the V grooves 53 toform a mitered joint 53" between each flange backing section 52 and theadjacent side apron backing section 44 as shown in Fig. 25; the V groove49 will close to form a mitered joint 49" between the front flangebacking sections 48 and the adjacent front apron backing section 42; theV groove B5 will close to form a mitered joint 65" between the angebacking section 64 and the shelf backing section 62 as shown in Fig. 26;and the V grooves 1 I will each close to form a mitered joint 1I"between the flange backing section 10 and the adjacent end backingsection 68 as shown in Fig. 27. As thus formed, the metal clad panelwill appear as diagrammatically illustrated in Fig. 24.

The bending formations above described may be facilitated by the use ofa clamping frame as more particularly illustrative in Figs. 28 to 3linclusive, which frame additionally serves to retain the formations inposition until the bonding adhesive has fully set. The metal tablefacing section I of the metal clad panel is positioned to be supportedupon a work table II1 having grooves I I8 and I I9 therein positionedand shaped to receive the rim formation h of the metal clad panel. Theerected shelf section f is positioned to abut against a fixed clampingmember I 20 and an adjustable clamping member I2| is adjusted to abutagainst the erected front apron section d. The

clamping member I2I is manipulated by adjusting bolts |23 `havingadjustingy heads |24, the bolts |23 being threaded through-a Xed bar |22so that the bolts |23may be manipulated to press the erected shelfsection f and the front apron section d of the metal clad panel betweenthe clamping members |29 and |2l. Suitable shaped wedges H8 arepositioned in the open groove 6| during this clamping operation so as toretain the table backing section a and the splash section c coplaner andprevent buckling thereof.

The clamping frame is also provided with a xed clamping member |25designed to abut against one of the side apron sections e, and anadjustable clamping member |26 designed to abut against the other sideapron section e. The side apron sections e are firmly clamped betweenthe clamping members |25 and |26- by the provision of adjusting bolts|21 threaded through a fixed bar |29, the bolts |21 haring adjustingheads |28 whereby the adjustable clamping member |26 may be manipulated.It will be noted by referring to Figs. 28 to 3l inclusive, that the endsections g of the splash portion are likewise ciamped between theclamping members |25 and |26. By means of a clamping frame as abovegenerally described, the apron sections d and e, the shelf section f,and the end sections g may be held firmly in their proper erectedposition.

Reinforcing and stiiening strips are then inserted under the inturnedange sections of the construction as also illustrated in Figs. 28 to3linclusive. A front stiifening strip 15, which may i'lrst be coated witha bonding adhesive, is inserted under the inturned front flange sectionlc. A reciprocable'pressure block |3| may be used to exert pressureagainst the inturned metal flange section I6 to retain the iiangesection in position, while screws or nails 11 are driven through theflange section |6 and into the underlying stiffening strip 15. Arearstiffeningstrip 18 is inserted under the inturned flange section sof the apron portion, the flange section s beingheld in posir-` tion bya reciprocable pressure block |32 while securing screws or nails 11 areapplied as shown in Fig. 30. Similarly, a side stiiening strip 16 isinserted under each inturned ange section r, the inturnedY liangesections 1' being then secured to the adjacent stiflening strips 16 asby screws or nails 11 while pressure isapplied to the flange sections bythe reciprocable pressure blocks |30 as shown in Fig. 29. Stiffeningstrips 19 are also inserted under the inturned ange sections t of theapron portion, the flange sections t being secured to the adjacentstiffening strips 19 as by screws or nails 11 while pressure is appliedto these flange sections by the reciprocable pressure blocks |30.

As thus constructed, the stiffening strips 15, 16, 18rand 19 retain theinturned fiange sections, and their associated apron sections d and eand their associated end sections g and shelf section f, in

firm fixed position until the bonding adhesive hasV taken a firm holdand after the partially formed counter top has been removed from theclampingv frame. y If no adhesive is used to secure the'stiffeningstrips firmly in position, a sufficient number of screws or nails 11 maybe applied to effect this result. It will be noted that the pres sureblocks |30 also serve to drive the inclined edges 41 of the side apronbacking sections 44 firmly against the adjacent inclined faces I3 of themetal facing sheet, and the pressure block I 3| also serves to drive theinclined edge 46 of the front apron backing section 42 firmly againstthe rear face of the rim formation 21of themetal 18 facing sheet asshown'in Fig. 30. Pressure' blocks |30, I3| and |32 also serve to insureclosetting mitered joints y49", 53", 63, 65,569" and 1|" as shown inFigs."29,` '30 and 31.

l'n the next operation the splashl panel portion c is erected-toextendsubstantially at right angles to the table portion was shown moreparticularly in Figs. 32and 33. The rounded edge |35 of an elongatedmandrel |35 is positioned along the bending line 3 of fthe metal sheetwhich serves to effect a rounded curvature 3' to the metal facing sheetat the base of the spla'shportion c as the same is swung into 'erectposition. When this operation is performed, the open groove @l of thebacking panelwill further gap open as shown in Fig. 33. A 'stiffeningbar 80, which may be made of wood or like brous material, is internttedagainst the rear face of the metal curved portion 3, the stiifening bar80 having a conforming curvature 8| as shown in Figs. 33 and 34. Thestiffening bar 801is so 4shaped and Vformed that the adjacent ends ofthefside stiffening strips 19 will firmly .abut against the face 8|ofthe stiifening bar 80, and the adjacent ends of the side stiieningstrip 16- will snugly abut against the face 8| of the stiieningY bar 88.The adjacent ends of the stiiening bar andthe stiifening strips15, 16,18 and 19 maybe secured together as by adhesive Aor metal fasteners. Asthus constructed the stiffening bar itl forms with the stifening strips15 and 16 a rectangular frame which gives further strength and rigidityto the-table portion ofthe construetion. The stiifening bar 80 alsoforms a rectangular stiienin'g frame with the stiffening strips 19 and18 to further stiifenand strengthen the formed splash portion of theconstruction; The counter top at this stage of assembly is strong andrigid and canL be handlediwithout dangerof deformation.

In event one or more sink wells are 'to' be incorporated as a part ofthe table portion a, the sink well b may be formed from a single sheet'of bright sheet metal'of sufficiently heavy'gauge to withstand denting.The sink well bas shown in Figs; 1 to 5 inclusive comprisesessentially'a bottom wall portion having a suitable drain openingtherein, the bottom portion 85 Abeing enclosed'by a surrounding sidewall portion 86 of any desired depth. The upper edge of the side wallVportion 86 is preferably provided with an outwardly flared flangeportion 81 which presents a recessedV shoulder 88. The outwardly 'flaredange portion 81 is designed to seat against the sloped/flange portion 9ofthe metal'tablesection with the lip portion I0 shaped vto snuglyoverlie and abut against the formed shoulder'portion 88 of the sink wellb. The flange portion 81of the sink well can be readily andexpeditiously attached to the inclined ange portion 9 of the metalfacingfsheet by applying a wireof'soldering or welding metal to theadjacent 'surfaces' Vof the flange v'portions 81 yand 9, which'metalwire'is melted to bond these langeportionsinto integral union by theapplication of heat and pressure to the abuttingange portions. Aleakproof joint is thusV provided which maybe-ren'- 8 0, as shown moreparticularly in Figs. 2, 3 and 5. The ller boards 90 `may have a notchedinterv lock 92 with the adjacent stiffening frame. Suitable ller boards9| are also inserted within the frame at the rear face of the apronportion c, the filler boards 9| having an interlocking joint 93 withtheV adjacent stiifening strips 18 and 19, and may also be interlockedto the stiffening bar 80. The filler boards 90 and 9| may also be bondedin position by theruse of a bonding adhesive. A suitable joint packing89 of bituminous or like material, may be used to fill the space betweenthe surrounding side wall portions 86 of the sink well b and theadjacent edges of the ller boards 90 and the adjacent edges of the tablebacking section 4|, as shown more particularly in Figs. 2 and 3. Y

To give the improved counter top construction a fully finishedappearance, a seam 91 of soldering or welding metal may be applied alongthe front Vertical corners of the counter top construction to adhesivelybond the adjacent inturned lip portions I8 and 23 of the metal facingsheet into integral union, as shown more particularly in Fig. 5. Thejointing seam may be burnished or polished so as to leave an invisiblejoint. The mitered joint between the adjacent ends I6' and 2 l of themetal flange sections I6 and 2|, as shown in Figs. 4 and 5, may also -bejoined into integral union by a seam 91' of soldering or welding metal,which joint can be burnished to p-resent an invisible juncture. Theadjacent inturned lip portions 30 and 34 of the splash portion may bebonded together into integral union by a seam 98 of a welding orsoldering metal, the seam joint being polished or burnished to renderthe joint substantially invisible. The adjacent ends 3| and 35' of themetal ange sections 28 and 35, as shown in Fig. 6, may be joined intointegral union by a seam 98 of soldering or welding metal, which may beburnished or polished to provide an invisible joint.

In event the counter top installation is such as to leave unconcealedthe exposed ends of the wood stiffening bar 80 shown in Fig. 34, theends thereof may be covered by a shoe i shaped from bright metal andpresenting a side wall portion 94 designed to fit 'over and cover theexposed end of the wood stiifening bar 80, the shoe having a. rearflange portion 95 adapted to be secured to the rear face of thestiffening bar 80, and a lower flange portion 98 designed to be securedto the under face of the stiffening bar 80. The facing portion 94 of theshoe i may be given a decorative triangular contour as shown in Fig. 34to simulate a bracket, or if desired, the face portion 94 of the shoemay be cut to conform to the end shape of the stiiening bar 8l! and tosnugly abut against the adjacent edges 25 and 25 of the end section 26and the adjacent apron section 20 of the metal facing sheet. The flushjoint thus formed at the metal edges may be closed by a seam of weldingor soldering metal suitably burnished and polished to leave an invisiblejoint. A deposit of soldering or welding metal may be applied to theends of the curved metal bend portion 3 so that the rear ends of the rimfaces |3 of the metal facing sheet will smoothly merge into the erectedsplash section 2 of the metal sheet.

Counter tops may be made in accordance with this invention to provide atable portion a of any desired width and length and to provide a splashportion c of any desired heighth and rearward depth. The apron sectionsd and e of the table portion may also be made of any desired heighth andthe inturned metal flange sections I6, 2|, 28 and 35 may be made toextend inwardly any desired distance. The raised rim h may extend alongonly the front edge of the table section, or along one or both sideedges of the table section, or along both the front and side edges ofthe table section, and can be fabricated by following the procedureabove described to provide a rim formation h of any desired heighth orwidth.

By reason of the use of fibrous backingsections which back up andsupport all exposed surfaces of the metal facing sheet, this improvedcounter top construction is free from metallic sound or ring whendrummed upon. The application of fibrous backing sections to the metalsheet prior to the bending formation thereof, permits the use of arelatively light gauge metal facing sheet, which is prevented fromwrinkling or warping during the manufacture and during use. Byconstructing the counter top in the manner above described, the exposedfaces of the metal sheet may be sanded and finished rapidly andeconomically in its flat condition and before any forming operations areexecuted thereon, thus avoiding the more difficult and time-consumingfinishing operations normally necessary after the counter top has beenconstructed. By forming the facing surfaces of the counter top from asingle piece of sheet metal, crevices and cracks in which foreign mattermay gather are substantially avoided. Extensive and time-consumingwelding and soldering operations heretofore necessary in the manufactureof metal clad counter tops as heretofore constructed, are also avoided.

Metal clad counter tops constructed as above described are light inweight, since strength is achieved by the use of relatively lightfibrous backing sections and wood or fibrous filler boards and strips.The counter top nevertheless possesses unusual strength and rigidity andwill not warp or deform. Since all exposed surface areas of the metalsheet, including the splash portion and the table portion with itsassociated rim formation and apron sections, are backed up by fibrousbacking sections, the finished metal surfaces cannot readily be dented,even though formed of a relatively light gauge metal sheet. Counter topsmay be manufactured in accordance with this invention to snugly t andseat upon any desired supporting structure S. The inturned flangesections I6, 2|, 35 and 28 may be made of any desired width so that theinner ends thereof, and securing screws or nails 1l, are concealed bythe structure upon which the counter top is supported. Counter tops,comprising essentially a table portion and a raised splash portion, andwith or without one or more sink wells associated with the tableportion, may be manufactured in accordance with the teachings of thisinvention on the mass production basis at greatly reduced cost ascompared with methods heretofore employed in the construction of suchmetal clad counter tops. These improved counter tops provide aconstruction of lasting utility, are sanitary, and highly attractive andappealing in appearance and nish.

While certain novel features of the invention have been disclosedherein, and are pointed out in the claims, it will be understood thatvarious omissions, substitutions, -and changes may be ing from thespirit of the invention.

